Electrical generator for a cementing manifold

ABSTRACT

Apparatuses and methods comprising a cementing head comprising a stationary body comprising a toothed ring; a rotating body disposed below the stationary body, the rotating body comprising an armature disposed inside the toothed ring; a battery disposed on the rotating body; and a wire connected to the armature and the battery.

BACKGROUND

1. Field

Embodiments disclosed herein relate to a cementing head for generating electrical power. More specifically, embodiments disclosed herein relate to apparatuses and methods for generating electrical power to actuate valves on cementing heads.

2. Background ART

A well-known method of drilling hydrocarbon wells involves disposing a drill bit at the end of a drill string and rotating the drill string from the surface utilizing either a top drive unit or a rotary table set in the drilling rig floor. As the well is formed, it is desirable to line the well bore. Thus, as drilling continues, progressively smaller diameter tubulars comprising casing and/or liner strings may be installed end-to-end to line the drilled borehole. As the well is drilled deeper, each string is run through and secured to the lower end of the previous string to line the borehole wall. The string is then cemented into place by flowing cement down the flowbore of the string and up the annulus formed by the string and the borehole wall.

To conduct the cementing operation, typically a cementing manifold is disposed between the top drive unit or rotary table and the drill string. Due to its position in the drilling assembly, the cementing manifold must suspend the weight of the drill pipe, contain pressure, transmit torque, and allow unimpeded rotation of the drill string. When utilizing a top drive unit, a separate inlet is typically provided to connect the cement lines to the cementing manifold. This allows cement to be discharged through the cementing manifold into the drill string without flowing through the top drive unit.

In operation, the cementing manifold allows fluids, such as drilling mud or cement, to flow there through while simultaneously enclosing and protecting from that flow, a series of projectiles, e.g., darts and spheres that are released on demand and in sequence to perform various operations downhole. Thus, as fluid flows through the cementing manifold, the darts and/or spheres are isolated from the fluid flow until they are ready for release.

Conventional cementing manifolds are available in a variety of configurations, with the most common configuration including a single sphere/single dart manifold. Using such a device, the sphere is dropped at a predetermined time during drilling to perform a particular function. For example, a sphere may be dropped to form a temporary seal or closure of the flowbore of the drill string or to actuate a downhole tool, such as a liner hanger, in advance of the cementing operation. Once the cement has been pumped downhole, the dart is dropped to perform another operation, such as wiping cement from the inner wall of a string of downhole tubular members.

Another common cementing manifold employs a single sphere/double dart configuration. The sphere may be released to actuate a downhole tool, for example, followed by the first dart being launched immediately ahead of the cement, and the second dart being launched immediately following the cement. Thus, the dual darts cap the “ends” of the cement and prevent the cement from mixing with drilling fluid as the cement is pumped downhole through the drill string. Each dart typically also performs another operation upon reaching the bottom of the drill string, such as latching into a larger dart to wipe cement from the string of downhole tubular members.

Whether the cementing manifold includes a single sphere/single dart or single sphere/double dart configuration, there are operational characteristics common to both. Loading and certification of the cementing manifold is not performed at the drill site. Instead, the sphere and dart(s) are typically loaded into the cementing manifold, with the customer present to verify the loading procedure, prior to transporting the cementing manifold to the drill site. Also, the majority of cementing jobs require a single sphere and at most two darts. Thus, a cementing manifold with a single sphere/single dart or single sphere/double dart configuration is sufficient for most cementing jobs.

Usually, two loaded cementing manifolds, including one for backup purposes, are then transported to the drilling rig. Prior to conducting a cementing job, rotation of the drill string is interrupted so that a loaded cementing manifold may be installed between the cementing swivel and drill string. In some configurations, the cementing manifold weighs several thousand pounds and may be 13 feet in length. Thus, given the weight and size of the cementing manifold, lifting it into position, which may be 20-30 feet above the rig floor, raises concerns for the safety of rig personnel. Therefore, it is desirable to reduce the size and weight of the cementing manifold so that installation of the cementing manifold may be both safer and easier.

Once the cementing manifold is installed, rotation of the drill string may resume, at least until the cementing operation begins. As previously stated, a sphere and dart(s) are released to perform various tasks at different stages of a cementing operation. During most cementing operations, actuation of valves to release the sphere and darts is performed manually by rig personnel. Rotation of the drilling string is again interrupted to allow rig personnel to traverse the thirty or so feet above the rig floor to the cementing manifold and manually actuate valves on the cementing manifold to release the sphere and darts, this too raises safety concerns. For this reason, some cementing manifolds may now be actuated to release the sphere and darts via remote control from the rig floor. Remote control actuation also allows rotation of the drill string to continue uninterrupted because rig personnel remain on the rig floor, a safe distance from the rotating equipment.

Verification that the sphere or dart has been released from the cementing manifold is performed by visual inspection. In the case of manual actuation, as the sphere or dart exits the cementing manifold, a flag on the cementing manifold is triggered. While this flag is designed to be visible from the rig floor, resetting the flag requires rig personnel to ascend the rig to manually reset the flag, there again raising safety concerns. In the case of remote control actuation, instead of a triggered flag, rig personnel view an indicating device that changes orientation on the cementing manifold when a sphere or dart has been released. However, the indicator is often shrouded within a plate assembly, requiring the rotating speed of the drill string be reduced so that rig personnel can clearly see the indicator orientation from the rig floor.

Thus, at the minimum, releasing a sphere or dart and verifying that release requires slowing the rotation of the drill string. Further, such release and verification frequently requires rig personnel to ascend the rig to the cementing manifold, raising concerns for the safety of rig personnel. Therefore, it would be an improvement to remotely actuate and remotely verify the release of spheres and darts from the cementing manifold, including resetting any involved devices prior to subsequent releases, without either the need to reduce the rotation speed of the drill string or for rig personnel to position themselves in proximity of the cementing manifold.

During multiple phase cementing operations, a pressure driven device is typically used to sequentially control the cementing head. Each time a pressurized medium is applied to the cementing head a cylinder turns a cam shaft to a predetermined angle, which passes the pressurized medium to a selective actuator and the actuator activates an associated valve on the cementing head. This operation may be repeated until all of the valves are activated and the shaft returns to its original position. In order to pressure drive the valves, a pressure chamber is mounted on the cementing head and is recharged with high pressure from one cementing operation to the next. The pressure chamber is typically large in size and requires assembly/disassembly between cementing jobs.

Once the cementing operation is complete, the cementing manifold may be empty. Typically, the cementing manifold is not reloaded and recertified on the drilling rig. Rather the empty manifold is removed from the drill string and stored on the drilling rig until it can be transported back to the service base for reloading and recertification.

Despite the valuable contributions in the art, it would be desirable to have apparatuses and methods for remotely actuating cementing manifolds.

SUMMARY

In one aspect, embodiments disclosed herein relate to a cementing head comprising a stationary body comprising a toothed ring; a rotating body disposed below the stationary body, the rotating body comprising an armature disposed inside the toothed ring; a battery disposed on the rotating body; and a wire connected to the armature and the battery.

In a further aspect, embodiments aim at a cementing head comprising a stationary body comprising an armature; a rotating body disposed at least partially inside the armature; a battery disposed on the rotating body; and a wire connected to the armature and the battery.

In yet a further aspect, embodiments pertain to methods of generating electrical power, the method comprising disposing a cementing head on a well head, the cementing head comprising a rotating body, an armature, a stationary body, and a battery; actuating the rotating body; generating an electrical voltage in the armature; and transferring the electrical voltage from the armature to the battery.

Other aspects and advantages will be apparent from the following description and the appended claims.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a schematic of a cementing operation according to embodiments of the present disclosure.

FIG. 2 is a side view of a cementing manifold according to embodiments of the present disclosure.

FIG. 3 is a side view of a cementing head according to embodiments of the present disclosure.

FIG. 4 is a side view of a cementing head according to embodiments of the present disclosure.

DETAILED DESCRIPTION

Embodiments disclosed herein relate generally to a cementing head for generating electrical power. More specifically, embodiments disclosed herein relate to apparatuses and methods for generating electrical power to actuate valves on cementing heads.

Certain terms are used throughout the following description and claims to refer to particular features or, components. As one skilled in the art will appreciate, different persons may refer to the same feature or component by different names. This document does not intend to distinguish between components or features that differ in name but not function. Further, the drawing figures are not necessarily to scale. Certain features and components herein may be shown exaggerated in scale or in somewhat schematic form, and some details of conventional elements may not be shown in interest of clarity and conciseness.

In the following discussion and in the claims, the terms “including” and “comprising” are used in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to . . . ” Also, the term “couple” or “couples” is intended to mean either an indirect or direct connection. Thus, if a first device couples to a second device, that connection may be through a direct connection, or through an indirect connection via other devices and connections.

FIG. 1 schematically depicts an exemplary drilling system, one of many in which cementing manifolds and methods disclosed herein may be employed The drilling system 100 includes a derrick 102 with a rig floor 104 at its lower end having an opening 106 through which drill string 108 extends downwardly into a well bore 110. The drill string 108 is driven rotatably by a top drive drilling unit 120 that is suspended from the derrick 102 by a traveling block 122. The traveling block 122 is supported and moveable upwardly and downwardly by a cabling 124 connected at its upper end to a crown block 126 and actuated by conventional powered draw works 128. Corrected below the top drive unit 120 is a kelly valve 130, a pup joint 132, a cementing swivel 160, and a cementing manifold, such as the canister fed cementing manifold 200, described more fully below. A flag sub 150, which provides a visual indication when a dart or sphere passes therethrough, is connected below the cementing manifold 200 and above the drill string 108. A drilling fluid line 134 routes drilling fluid to the top drive unit 120, and a cement line 136 routes cement through a valve 138 to the swivel 160. Tie-off connections 162, 164 secure the cementing swivel 160 to the derrick 102.

FIG. 1 depicts one example of a drilling environment in which the cementing manifolds and methods disclosed herein may be utilized. One of ordinary skill in the art will readily appreciate, however, that the embodiments disclosed herein are not limited to use with a particular type of drilling system. Rather, these embodiments may be utilized in other drilling environments such as, for example, to cement casing into an offshore well bore.

FIG. 2 schematically depicts a representative cementing manifold connected above to a cementing swivel and below to a drill string. As described in reference to and shown in FIG. 1, the cementing swivel 160 and the cementing manifold 200 are coupled to a drill string 108. Cement is provided to the cementing swivel 160 through cement line 136. The cement passes through the cementing swivel 160 and into the cementing manifold 200 through a fluid entry port 202. The cement continues through the cementing manifold 200 via a through-passage, such as a flowbore, and finally exits the cementing manifold through a fluid exit port 204. As the cement flows through the cementing manifold 200, projectiles, such as a dart and/or a sphere, may be released into the cement flow at desired times.

Referring to FIG. 3, a side perspective view of a cementing manifold according to embodiments of the present disclosure is shown. The cementing head 300 is illustrated having a lower tubular body 301 (i.e., a rotating body) and an upper tubular body 302 (i.e., a stationary body). Lower tubular body 301 is configured to rotate during a cementing operation, while upper tubular body 302 is configured to remain relatively stationary. Lower tubular body 301 is coupled to a rotor 303 at a first end 304 of lower tubular body 301. The rotor 303 is coupled to lower tubular body 301 so that as lower tubular body 301 rotates, rotor 303 also rotates. Rotor 303 may be coupled to lower tubular body 301 using various connection techniques, such as threadable connections, screws, rivets, brazing, and the like.

Lower tubular body 301 also includes various electrical components, such as a plurality of torque converters 305, one or more batteries 306, and a plurality of valves (not independently shown). Torque converters 305 are disposed on the outside of lower tubular body 301 and are in electrical communication with the one or more valves. The torque converters 305 are configured to convert direct current (“DC”) to alternating current (“AC”), such that when a selected circuit is closed, the torque converter 305 drives an associated valve, opening or closing the valve, and thereby controlling the cementing operation.

The plurality of torque converters 305, in embodiments, may be electrically connected to one or more batteries 306. The batteries may be used to store energy produced by the generator, which will be explained in detail below. Thus, in certain embodiments, the stored energy may be transferred to one or more torque converters 305 for use in actuating one or more valves. The connections 307 between the one or more batteries 306 and the torque convertors 305 may be through any type of conductive wire known in the industry. In embodiments separate connections 307 may be provided between individual torque converters 305 and the one or batteries 306, while in other embodiments, a single connection 307 may be established between all of the one or more batteries 306 and the torque converters 305.

The one or more batteries 306 may also be surrounded by a heat jacket (not illustrated), such that if cold temperatures are encountered, the one or more batteries 306 will continue to hold a charge. Depending on the types of torque converters 305 used, a heat jacket may surround one or more of the torque converters 305 as well. Other components may also be present with respect to lower tubular body 301. For example, in certain embodiments, an outer protective sleeve may surround all or part of lower tubular body 301, including the valves, torque converters 305 and/or battery 306.

As explained above, the lower tubular body 301 is coupled to rotor 303. Rotor 303 is configured to rotate along with the rotation of lower tubular body 301 during use of the cementing head 300. In this embodiment, rotor 303 includes a plurality of wires or a coil and constitutes the voltage inducing component of the generator. Rotor 303 is disposed partially inside an armature 308. Armature 308 is stationary and includes a toothed ring or gear 309 configured to electrically interact with rotor 303. A plurality of electromagnets or permanent magnets may be disposed in toothed ring 309 (for example through press-fitting) and thus, the toothed ring 309 constitutes the magnetic field component of the electrical generator. As rotor 303 rotates during use of cementing head 300, a change in magnetic flux density at the coils induces an electrical voltage that may be transferred to armature 308. The mechanical power of the rotating cement head 300 is thus converted to electrical power, such that the armature 308 electromotive force drives the armature 308 current, which may be transferred and stored in the battery 306. Alternatively, the electrical power may be transferred directly to the torque converters 306 for use in actuating valves of the cement head 300.

The armature 308 is connected to the battery 306 and/or torque converters 305 through connections 307. In certain aspects, a swivel 310 may provide the connection between connections 307 and armature 308, as lower tubular body 301 rotates while upper tubular body 302, including the stationary armature 308, does not rotate.

Referring to FIG. 4, a side perspective view of a cementing manifold according to embodiments of the present disclosure is shown. Many of the components are the same as those described with respect to FIG. 3; however, the method by which energy is generated differs. Accordingly, like number represent like components, even though the way the components are used may differ.

The cementing head 300 is illustrated having a lower tubular body 301 and an upper tubular body 302. Lower tubular body 301 is configured to rotate during a cementing operation, while upper tubular body 302 is configured to remain relatively stationary. Lower tubular body 301 is coupled to a rotor 303 at a first end 304 of lower tubular body 301. The rotor 303 is coupled to lower tubular body 301 so that as lower tubular body 301 rotates, rotor 303 also rotates.

Lower tubular body 301 also includes various electrical components, such as a plurality of torque converters 305, one or more batteries 306, and a plurality of valves (not independently shown), as discussed above with respect to FIG. 3. Torque converters 305 are disposed on the outside of lower tubular body 301 and are in electrical communication with the one or more valves. The torque converters 305 are configured to convert DC to AC such that when a selected circuit is closed, the torque converter 305 drives an associated valve, opening or closing the valve, and thereby controlling the cementing operation.

The plurality of torque converters 305, in embodiments, may be electrically connected to one or more batteries 306. The connections 307 between the one or more batteries 306 and the torque convertors 305 may be through any type of conductive wire known in the industry. In certain embodiments separate connections 307 may be provided between individual torque converters 305 and the one or batteries 306, while in other embodiments, a single connection 307 may be established between all of the one or more batteries 306 and the torque converters 305. In embodiments, a single connection 307 transfers generated energy to battery 306, through a torque converter 305 a, and then to other individual torque converters 305 b-305 d.

In embodiments, lower tubular body 301 is coupled to rotor 303. Rotor 303 is configured to rotate along with the rotation of lower tubular body 301 during use of the cementing head 300. Rotor 303 is coupled to an armature 308, which is wound by wire to produce a coil. Thus, as rotor 303 rotates, armature 308 also rotates. Armature 308 is disposed inside toothed ring or gear 309, which may also include a plurality of electromagnets or permanent magnets disposed therein. Toothed ring or gear 309 is stationary, thus, as rotor 303 rotates armature 308 a change in magnetic flux density induces an electrical voltage in the coil or wires in armature 308. Thus, the mechanical power is converted to electrical power so that the electrical power may be transferred to either battery 306 or torque converters 305 for actuating one or more valves.

In embodiments, the armature 308 is connected to the battery 306 and/or torque converters 305 through connections 307. As both lower tubular body 301, including rotor 303 rotate with armature 308, the connections 307 may be directly between battery 305 and armature 308. While a swivel (not shown) may be used, the swivel is not necessary.

Those of ordinary skill in the art will appreciate that the configuration of rotor 303, armature 308, and toothed ring 309 may vary, and any of the rotor 303, armature 308 and toothed ring 309 may rotate or be stationary, regardless of the naming conventions used herein. Those of ordinary skill in the art will appreciate that the rotor 303, armature 308, and toothed ring 309 may be either a magnetic field component or a power-producing component, depending on design requirements of cementing head 300. For example, in alternate embodiments, a toothed ring 309 having a plurality of magnets may be coupled to rotor 303, thus, the magnetic field generating component rotates with the lower tubular body 301. In embodiments, the coil may be stationary and communicate directly with armature 308, which may also be stationary. In embodiments, the toothed ring 309 may be coupled to the rotor 303 as well as the armature 309, and all three components may be configured to rotate during operation of the cementing head 300. In such an embodiment, the coil would remain stationary, and the electrical voltage induced by the coil would be transferred to the armature, which is rotating, for transference to one or more of the batteries 306 and/or torque converters 305.

In embodiments, cementing head 300 may also include a radio frequency receiver/transceiver (not illustrated) connected to one or more torque converters 305 and/or batteries 306. The radio frequency receiver/transceiver may be used to wirelessly provide a signal to actuate one or more of the valves, thereby allowing the cementing operation to be controlled from a remote location. The radio frequency signal may be generated by an operator working from a computer, such as a laptop.

In embodiments, additional components may also be used to further enhance the electrical power generation. For example, in embodiments a commutator may be used to more efficiently remove power from the generator. Additionally, speed of rotation of the lower tubular body 301 may be modulated to adjust the voltage applied to the battery 306.

During operation of embodiments of the above described cementing head, and in the interests of generating electrical power during the cementing operation, an operator may dispose a cementing head on a well head. The cementing head may include a rotating body, an armature, a stationary body, and a battery. The rotating body may then be actuated as the cementing operation commences, thereby resulting in an electrical voltage being generated in the armature. The generated electrical voltage may subsequently be transferred to the battery or directly to torque converters allowing for the actuation of one or more cementing valves of the cementing head. The cementing operation may thus be controlled by sending signals, such as radio frequency signals, to the one or more valves.

While the present disclosure has been described with respect to a limited number of embodiments, those skilled in the art, having benefit of this disclosure, will appreciate that other embodiments may be devised which do not depart from the scope of the disclosure as described herein. Accordingly, the scope of the disclosure should be limited only by the attached claims. 

What is claimed:
 1. A cementing head comprising: a stationary body comprising a toothed ring; a rotating body disposed below the stationary body, the rotating body comprising an armature disposed inside the toothed ring; a battery disposed on the rotating body; and a wire connected to the armature and the battery.
 2. The cementing head of claim 1, further comprising at least one torque converter disposed on the rotating body.
 3. The cementing head of claim 2, wherein the torque converter is electrically connected to the battery.
 4. The cementing head of claim 2, wherein the torque converter is electrically connected to the armature.
 5. The cementing head of claim 2, wherein the torque converter is electrically connected to the battery and the armature.
 6. The cementing head of claim 1, further comprising a swivel disposed on the armature, wherein the wire is connected to the swivel.
 7. The cementing head of claim 1, further comprising a heat jacket disposed over the battery.
 8. The cementing head of claim 1, further comprising a radio frequency receiver/transceiver disposed on the rotating body.
 9. The cementing head of claim 1, wherein the toothed ring comprises a plurality of magnets.
 10. The cementing head of claim 6, wherein the armature comprises a coil of wire.
 11. A cementing head comprising: a stationary body comprising an armature; a rotating body disposed at least partially inside the armature; a battery disposed on the rotating body; and a wire connected to the armature and the battery.
 12. The cementing head of claim 11, further comprising at least one torque converter disposed on the rotating body.
 13. The cementing head of claim 12, wherein the torque converter is electrically connected to the battery.
 14. The cementing head of claim 12, wherein the torque converter is electrically connected to the armature.
 15. The cementing head of claim 12, wherein the torque converter is electrically connected to the battery and the armature.
 16. The cementing head of claim 11, further comprising a heat jacket disposed over the battery.
 17. The cementing head of claim 11, further comprising a radio frequency receiver/transceiver disposed on the rotating body.
 18. The cementing head of claim 11, wherein the rotating body comprises a plurality of magnets.
 19. A method of generating electrical power, the method comprising: disposing a cementing head on a well head, the cementing head comprising a rotating body, an armature, a stationary body, and a battery; actuating the rotating body; generating an electrical voltage in the armature; and transferring the electrical voltage from the armature to the battery.
 20. The method of claim 19, further comprising: transferring the electrical voltage to a torque converter; and actuating a cementing valve on the cementing head. 